Water Pump Replacement. Chevrolet PJJ 2000

For 1990-2009 cars

### Removal Procedure 2.4L

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Drain the coolant. Recover the coolant. Refer to Cooling System Draining and Filling .
3. Disconnect the oxygen sensor (O2S) connector.
4. Remove the upper exhaust manifold heat shield. Refer to Exhaust Manifold Replacement in Engine Mechanical - 2.4L.
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Remove the exhaust manifold brace to manifold bolt.
7. Break loose the manifold to exhaust pipe bolts.
8. Remove the radiator outlet pipe assembly to coolant pump cover (2) bolts (1).

Notice: Do not rotate the flex coupling more than 4 degrees. Damage to the flex coupling may occur.

9. Remove the exhaust manifold pipe from the exhaust manifold. Pull down and back on the exhaust manifold pipe in order to disengage the pipe from the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Mechanical - 2.4L.
10. Remove the radiator outlet pipe (1) from the oil pan (2).

• | With a manual transaxle, remove the exhaust manifold brace.

• | Keep the radiator inlet hose attached. Pull down on the radiator outlet pipe in order to disengage the pipe from the coolant pump. Leave the radiator outlet pipe hanging.

11. Lower the vehicle.
12. Remove the following parts in order:

12.1. | The brake vacuum pipe from the cam housing

12.2. | The exhaust manifold to cylinder head retaining nuts

12.3. | The exhaust manifold

12.4. | The seals and gaskets of the exhaust manifold, refer to Exhaust Manifold Replacement in Engine Mechanical - 2.4L.

13. Remove the front timing chain cover. Refer to Timing Chain Housing Replacement in Engine Mechanical - 2.4L.
14. Remove the timing chain tensioner. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement in Engine Mechanical - 2.4L.
15. Remove the coolant pump cover to cylinder block bolts.
16. Remove the coolant pump to timing chain housing nuts.
17. Remove the coolant pump cover (3) and the coolant pump (2) and the gaskets (1).
18. Remove the coolant pump cover to coolant pump assembly bolts (4).
19. Clean all sealing surfaces.

### Installation Procedure

Important: Before you install the coolant pump, read the entire procedure. Pay special attention to the tightening sequences in order to avoid part damage and to provide proper sealing.

1. Install the coolant pump cover (3) and the gasket (1) to the coolant pump (2).

1.1. | Lubricate the splines of the coolant pump drive with Chassis Grease GM P/N 1051344, or equivalent.

1.2. | Install the coolant pump cover to coolant pump bolts (4), then hand tighten the bolts.

2. Install the coolant pump and the coolant pump cover assembly in position on the engine block.
3. Install the coolant pump cover to block bolts. Hand tighten the bolts.
4. Install the coolant pump to timing chain housing nuts. Hand tighten the nuts.
5. Lubricate the o-ring on the radiator outlet pipe with an antifreeze solution.

5.1. | Slide the outlet pipe into the coolant pump cover.

5.2. | Install the bolts. Hand tighten the bolts.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Tighten the coolant pump assembly to timing chain housing nuts.

Tighten
Tighten the nuts to 26 N·m (19 lb ft).

7. Tighten the coolant pump cover to water pump bolts (4).

Tighten
Tighten the bolts to 14 N·m (124 lb in).

8. Tighten the coolant pump cover to engine block bolts.

Tighten
Tighten the bottom bolt first. Tighten the bolts to 26 N·m (19 lb ft).

9. Tighten the radiator outlet pipe to coolant pump cover (2) bolts (1).

Tighten
Tighten the bolts to 14 N·m (124 lb in).

10. Using new gaskets, install the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Mechanical - 2.4L.
11. Install the exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence and tighten to specification. Refer to Exhaust Manifold Replacement in Engine Mechanical - 2.4L.
12. Connect the brake vacuum pipe to the cam housing.
13. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
14. Index the exhaust manifold bolts into the exhaust pipe flange.
15. Install the exhaust pipe to the exhaust manifold and the bolts. Turn both bolts in evenly in order to avoid cocking the exhaust pipe and binding the bolts. Turn in the bolts until the bolts are fully seated. Refer to Exhaust Manifold Replacement in Engine Mechanical - 2.4L.
16. Install the heater outlet pipe bracket to the transmission.
17. Install the radiator outlet pipe to the oil pan. Install the bolts. With a manual transaxle, install the exhaust manifold brace.

Tighten
Tighten the outlet pipe to oil pan bolt to 25 N·m (18 lb ft).

18. Install the timing chain tensioner. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement in Engine Mechanical - 2.4L.
19. Install the timing chain cover. Refer to Timing Chain Housing Replacement in Engine Mechanical - 2.4L.
20. Lower the vehicle.
21. Install the exhaust manifold brace to manifold bolt.
22. Tighten the manifold to exhaust pipe nuts to specification.
23. Install the exhaust manifold upper heat shield.
24. Connect the oxygen sensor (O2S) connector.
25. Fill the radiator with coolant until the coolant level reaches the heater hose coolant outlet. Then install the hose (this action assists in a complete cylinder block fill). Continue the filling procedure. Refer to Cooling System Draining and Filling .
26. Connect the negative battery cable.

Tighten
Tighten the negative battery cable bolt to 15 N·m (11 lb ft).

27. Start the engine. After the engine reaches normal operating temperature, check for coolant leaks.